WO2007008450A1 - Low gloss thermoplastic composition, method of making, and articles formed therefrom - Google Patents

Low gloss thermoplastic composition, method of making, and articles formed therefrom Download PDF

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Publication number
WO2007008450A1
WO2007008450A1 PCT/US2006/025527 US2006025527W WO2007008450A1 WO 2007008450 A1 WO2007008450 A1 WO 2007008450A1 US 2006025527 W US2006025527 W US 2006025527W WO 2007008450 A1 WO2007008450 A1 WO 2007008450A1
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WIPO (PCT)
Prior art keywords
polycarbonate
thermoplastic composition
styrene
acrylonitrile
low gloss
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PCT/US2006/025527
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English (en)
French (fr)
Inventor
Jing Chen
Theo Hoeks
Xinmin Yang
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General Electric Company
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Application filed by General Electric Company filed Critical General Electric Company
Priority to AT06774334T priority Critical patent/ATE475692T1/de
Priority to EP06774334A priority patent/EP1951811B1/en
Priority to DE602006015843T priority patent/DE602006015843D1/de
Priority to JP2008520301A priority patent/JP2009500495A/ja
Publication of WO2007008450A1 publication Critical patent/WO2007008450A1/en

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L69/00—Compositions of polycarbonates; Compositions of derivatives of polycarbonates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L35/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a carboxyl radical, and containing at least one other carboxyl radical in the molecule, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
    • C08L35/06—Copolymers with vinyl aromatic monomers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
    • C08L51/04—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to rubbers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins

Definitions

  • This disclosure relates to polycarbonate compositions, and in particular to low gloss polycarbonate compositions, methods of manufacture, and uses thereof.
  • Thermoplastics having a low gloss finish are useful in the manufacture of articles and components for a wide range of applications, from automobile components, to decorative articles, to housings for electronic appliances, such as computers.
  • a low gloss finish for a plastic article can be obtained using different methods. Mechanically texturing a plastic surface has long been used, but this type of surface finish is prone to wear and ultimately increases in gloss with use. Further, mechanical texturing adds processing steps and increases manufacturing costs. Modifications to the moldable thermoplastic composition itself is therefore desirable, whereupon an article can have a low gloss surface immediately after processes such as molding, casting, extruding, or rolling of a suitable low gloss composition. Excellent mechanical properties are also desired in a low gloss thermoplastic composition for use in these applications.
  • Polycarbonates which have excellent mechanical properties, can be used in applications as described above.
  • Low gloss finishes for polycarbonates can be attained by adding gloss-reducing fillers and additives such as particulate silica, or resins with gloss reducing functionality; however the usefulness of such blends can be mitigated by reduction in or loss of mechanical properties such as, for example, impact strength and ductility retention.
  • thermoplastic compositions comprising polycarbonates.
  • Desirable features of such materials include both excellent mechanical properties and ease of manufacture.
  • the mechanical properties of the low gloss thermoplastic composition are desirably comparable to those of high gloss polycarbonate.
  • thermoplastic composition comprising a resin composition comprising a polycarbonate, an acrylonitrile-styrene-acrylate terpolymer, and a low gloss additive comprising the reaction product of a polyepoxide and an ethylenically unsaturated nitrile containing copolymer, wherein the 60° gloss of the thermoplastic composition is measured to be less than or equal to 90 GU on 3 millimeter color chips according to ASTM D2457.
  • a method of preparing a thermoplastic composition comprises melt-combining a polycarbonate, an acrylonitrile-styrene-acrylate terpolymer, and a low gloss additive comprising the reaction product of a polyepoxide and an ethylenically unsaturated nitrile containing copolymer, wherein the melt combining is done at a temperature of 220 to 300 0 C.
  • an article comprises the above-described thermoplastic composition.
  • thermoplastic composition comprising a resin composition comprising a polycarbonate, 1 to 30 weight percent (wt%) of an acrylonitrile-styrene-acrylate terpolymer, and a low gloss additive, has suitable low gloss performance, in addition to excellent mechanical properties.
  • acrylonitrile-styrene-acrylate terpolymer shows less increase in measured gloss and better mechanical properties than seen in comparable loadings of acrylonitrile- butadiene-styrene (ABS) impact modifier.
  • ABS acrylonitrile- butadiene-styrene
  • the resin composition comprises a polycarbonate.
  • polycarbonate and “polycarbonate resin” means compositions having repeating structural carbonate units of the formula (1):
  • each R 1 is an aromatic organic radical, for example a radical of the formula (2):
  • each of A and A is a monocyclic divalent aryl radical and Y is a bridging radical having one or two atoms that separate A 1 from A 2 .
  • one atom separates A from A .
  • Illustrative non-limiting examples of radicals of this type are -O-, -S-, -S(O)-, -S(O 2 )-, -C(O)-, methylene, cyclohexyl- methylene, 2-[2.2.1]-bicycloheptylidene, ethylidene, isopropylidene, neopentylidene, cyclohexylidene, cyclopentadecylidene, cyclododecylidene, and adamantylidene.
  • the bridging radical Y 1 may be a hydrocarbon group or a saturated hydrocarbon group such as methylene, cyclohexylidene, or iso
  • Polycarbonates may be produced by the interfacial reaction of dihydroxy compounds having the formula HO-R '-OH, which includes dihydroxy compounds of formula (3)
  • R a and R b each represent a halogen atom or a monovalent hydrocarbon group and may be the same or different; p and q are each independently integers of 0 to 4; and X a represents one of the groups of formula (5): R c R e
  • R c and R d each independently represent a hydrogen atom or a monovalent linear or cyclic hydrocarbon group and R e is a divalent hydrocarbon group.
  • suitable dihydroxy compounds include the following: resorcinol, 4-bromoresorcinol, hydroquinone, 4,4'-dihydroxybiphenyl, 1,6- dihydroxynaphthalene, 2,6-dihydroxynaphthalene, bis(4-hydroxyphenyl)methane, bis(4-hydroxyphenyl)di ⁇ henylmethane, bis(4-hydroxyphenyl)-l-naphthylmethane, 1 ,2-bis(4-hydroxyphenyl)ethane, 1 , 1 -bis(4-hydroxyphenyl)- 1 -phenylethane, 2-(4- hydroxyphenyl)-2-(3-hydroxyphenyl)propane, bis(4-hydroxyphenyl)phenylmethane, 2,2-bis(4-hydroxy-3-bromophenyl)propane, 1,1-bis (hydroxyphenyl)cyclopentane, l,l-bis
  • bisphenol compounds that may be represented by formula (3) include l,l-bis(4-hydroxyphenyl) methane, l,l-bis(4-hydroxyphenyl) ethane, 2,2-bis(4-hydroxyphenyl) propane (hereinafter "bisphenol A” or "BPA”), 2,2- bis(4-hydroxyphenyl) butane, 2,2-bis(4-hydroxyphenyl) octane, l,l-bis(4- hydroxyphenyl) propane, l,l-bis(4-hydroxyphenyl) n-butane, 2,2-bis(4-hydroxy-l- methylphenyl) propane, l,l-bis(4-hydroxy-t-butylphenyl) propane, 3,3-bis(4- hydroxyphenyl) phthalimidine, 2-phenyl-3,3-bis(4-hydroxyphenyl) phthalimidine (PPPBP), and l,l-bis(4-hydroxy-3-methylphenyl)cycl
  • Branched polycarbonates are also useful, as well as blends of a linear polycarbonate and a branched polycarbonate.
  • the branched polycarbonates may be prepared by adding a branching agent during polymerization.
  • branching agents include polyfunctional organic compounds containing at least three functional groups selected from hydroxyl, carboxyl, carboxylic anhydride, haloformyl, and mixtures of the foregoing functional groups.
  • trimellitic acid trimellitic anhydride
  • trimellitic trichloride tris-p-hydroxy phenyl ethane, isatin-bis-phenol, tris- phenol TC (l,3,5-tris((p ⁇ hydroxyphenyl)isopropyl)benzene), tris-phenol PA (4(4(1,1- bis(p-hydroxyphenyl)-ethyl) alpha, alpha-dimethyl benzyl)phenol), 4-chloroformyl phthalic anhydride, trimesic acid, and benzophenone tetracarboxylic acid.
  • the branching agents may be added at a level of 0.05 to 2.0 wt%. All types of polycarbonate end groups are contemplated as being useful in the polycarbonate composition, provided that such end groups do not significantly affect desired properties of the thermoplastic compositions.
  • the polycarbonate is a linear homopolymer derived from bisphenol A, in which each of A and A is p-phenylene and Y is isopropylidene.
  • the polycarbonates may have an intrinsic viscosity, as determined in chloroform at 25°C, of 0.3 to 1.5 deciliters per gram (dl/g), specifically 0.45 to 1.0 dl/g.
  • the polycarbonates may have a weight average molecular weight of 10,000 to 100,000, specifically 15,000 to 50,000 as measured by gel permeation chromatography using a crosslinked styrene-divinyl benzene column, at a sample concentration of 1 milligram per milliliter, and as calibrated with polystyrene standards.
  • the polycarbonate has flow properties suitable for the manufacture of thin articles.
  • Melt volume flow rate (often abbreviated MVR) measures the rate of extrusion of a thermoplastics through an orifice at a prescribed temperature and load.
  • Polycarbonates suitable for the formation of thin articles can have an MVR, measured at 300 °C/1.2 kg, of 1 to 35 cubic centimeter per 10 minutes (cc/10 min), specifically 2 to 30 cc/10 min. Mixtures of polycarbonates of different flow properties may be used to achieve the overall desired flow property.
  • the polycarbonate can have a light transmission greater than or equal to 55%, specifically greater than or equal to 60% and more specifically greater than or equal to 70%, as measured according to ASTM D1003-00.
  • the polycarbonate can have a haze less than or equal to 50%, specifically less than or equal to 40%, and most specifically less than or equal to 30%, as measured according to ASTM D1003-00.
  • Polycarbonates and “polycarbonate resin” as used herein may further include blends of polycarbonates with other copolymers comprising carbonate chain units.
  • a specific suitable copolymer is a polyester carbonate, also known as a copolyester- polycarbonate. Such copolymers further contain, in addition to recurring carbonate chain units of the formula (1), repeating units of formula (6):
  • D is a divalent radical derived from a dihydroxy compound, and may be, for example, a C 2- io alkylene radical, a C 6-2 O alicyclic radical, a C 6-2 O aromatic radical or a polyoxyalkylene radical in which the alkylene groups contain 2 to 6 carbon atoms, specifically 2, 3, or 4 carbon atoms; and T divalent radical derived from a dicarboxylic acid, and may be, for example, a C 2-1O alkylene radical, a C 6-2O alicyclic radical, a C 6- 2o alkyl aromatic radical, or a C 6-20 aromatic radical.
  • D is a C 2-6 alkylene radical. In another embodiment, D is derived from an aromatic dihydroxy compound of formula (7):
  • each R f is independently a halogen atom, a C 1-1O hydrocarbon group, or a C 1- io halogen substituted hydrocarbon group, and n is 0 to 4.
  • the halogen is usually bromine.
  • compounds that may be represented by the formula (7) include resorcinol, substituted resorcinol compounds such as 5-methyl resorcinol, 5- ethyl resorcinol, 5-pro ⁇ yl resorcinol, 5-butyl resorcinol, 5-t-butyl resorcinol, 5- phenyl resorcinol, 5-cumyl resorcinol, 2,4,5,6-tetrafluoro resorcinol, 2,4,5,6- tetrabromo resorcinol, or the like; catechol; hydroquinone; substituted hydroquinones such as 2-methyl hydroquinone, 2-ethyl hydroquinone, 2-propyl hydroquinone,
  • aromatic dicarboxylic acids that may be used to prepare the polyesters include isophthalic or terephthalic acid, l,2-di(p-carboxyphenyl)ethane, 4,4'- dicarboxydiphenyl ether, 4,4'-bisbenzoic acid, and mixtures comprising at least one of the foregoing acids. Acids containing fused rings can also be present, such as in 1,4-, 1,5-, or 2,6-naphthalenedicarboxylic acids. Specific dicarboxylic acids are terephthalic acid, isophthalic acid, naphthalene dicarboxylic acid, cyclohexane dicarboxylic acid, or mixtures thereof.
  • a specific dicarboxylic acid comprises a mixture of isophthalic acid and terephthalic acid wherein the weight ratio of terephthalic acid to isophthalic acid is 91:1 to 2:98.
  • D is a C 2-6 alkylene radical and T is p-phenylene, m-phenylene, naphthalene, a divalent cycloaliphatic radical, or a mixture thereof.
  • This class of polyester includes the poly(alkylene terephthalates).
  • polyester polycarbonates can comprise carbonate units as described hereinabove.
  • Carbonate units of formula (1) may also be derived from aromatic dihydroxy compounds of formula (7), wherein specific carbonate units are resorcinol carbonate units.
  • the polyester unit of a polyester-polycarbonate can be derived from the reaction of a combination of isophthalic and terephthalic diacids (or derivatives thereof) with resorcinol, bisphenol A, or a combination comprising one or more of these, wherein the molar ratio of isophthalate units to terephthalate units is 91:9 to 2:98, specifically 85:15 to 3:97, more specifically 80:20 to 5:95, and still more specifically 70:30 to 10:90.
  • the polycarbonate units can be derived from resorcinol and/or bisphenol A, in a molar ratio of resorcinol carbonate units to bisphenol A carbonate units of 0:100 to 99:1, and the molar ratio of the mixed isophthalate- terephthalate polyester units to the polycarbonate units in the polyester- polycarbonate can be 1:99 to 99:1, specifically 5:95 to 90:10, more specifically 10:90 to 80:20. Where a blend of polyester-polycarbonate with polycarbonate is used, the ratio of polycarbonate to polyester-polycarbonate in the blend can be, respectively, 1:99 to 99:1, specifically 10:90 to 90:10.
  • the polyester-polycarbonates may have a weight-averaged molecular weight (Mw) of 1,500 to 30,000, specifically 1,700 to 20,000, and more specifically 2,000 to 10,000.
  • Mw weight-averaged molecular weight
  • Molecular weight determinations are performed using gel permeation chromatography (GPC), using a crosslinked styrene-divinylbenzene column and calibrated to polystyrene references. Samples are prepared at a concentration of about 1 mg/ml, and are eluted at a flow rate of about 1.0 ml/min.
  • Suitable polycarbonates can be manufactured by processes such as interfacial polymerization and melt polymerization.
  • reaction conditions for interfacial polymerization may vary, an exemplary process generally involves dissolving or dispersing a dihydric phenol reactant in aqueous caustic soda or potash, adding the resulting mixture to a suitable water-immiscible solvent medium, and W
  • a carbonate precursor in the presence of a suitable catalyst such as triethylamine or a phase transfer catalyst, under controlled pH conditions, e.g., 8 to 10.
  • a suitable catalyst such as triethylamine or a phase transfer catalyst
  • the most commonly used water immiscible solvents include methylene chloride, 1,2-dichloroethane, chlorobenzene, toluene, and the like.
  • Suitable carbonate precursors include, for example, a carbonyl halide such as carbonyl bromide or carbonyl chloride, or a haloformate such as a bishaloformates of a dihydric phenol (e.g., the bischloroformates of bisphenol A, hydroquinone, or the like) or a glycol (e.g., the bishaloformate of ethylene glycol, neopentyl glycol, polyethylene glycol, or the like). Combinations comprising at least one of the foregoing types of carbonate precursors may also be used.
  • a carbonyl halide such as carbonyl bromide or carbonyl chloride
  • a haloformate such as a bishaloformates of a dihydric phenol (e.g., the bischloroformates of bisphenol A, hydroquinone, or the like) or a glycol (e.g., the bishaloformate of ethylene glycol
  • a chain stopper (also referred to as a capping agent) may be included during polymerization.
  • the chain-stopper limits molecular weight growth rate, and so controls molecular weight in the polycarbonate.
  • a chain-stopper may be at least one of mono-phenolic compounds, mono-carboxylic acid chlorides, and/or mono- chloroformates.
  • mono-phenolic compounds suitable as chain stoppers include monocyclic phenols, such as phenol, C 1-22 alkyl-substituted phenols, p-cumyl- phenol, p-tertiary-butyl phenol, hydroxy diphenyl; monoethers of diphenols, such as ⁇ -methoxyphenol.
  • Alkyl-substituted phenols include those with branched chain alkyl substituents having 8 to 9 carbon atoms.
  • a mono-phenolic UV absorber may be used as capping agent.
  • Such compounds include 4-substituted-2- hydroxybenzophenones and their derivatives, aryl salicylates, monoesters of diphenols such as resorcinol monobenzoate, 2-(2-hydroxyaryl)-benzotriazoles and their derivatives, 2-(2-hydroxyaryl)-l,3,5-triazines and their derivatives, and the like.
  • mono-phenolic chain-stoppers include phenol, p-cumylphenol, and/or resorcinol monobenzoate.
  • Mono-carboxylic acid chlorides may also be suitable as chain stoppers. These include monocyclic, mono-carboxylic acid chlorides such as benzoyl chloride, C 1-22 alkyl-substituted benzoyl chloride, toluoyl chloride, halogen-substituted benzoyl chloride, bromobenzoyl chloride, cinnamoyl chloride, 4-nadimidobenzoyl chloride, and mixtures thereof; polycyclic, mono-carboxylic acid chlorides such as trimellitic anhydride chloride, and naphthoyl chloride; and mixtures of monocyclic and polycyclic mono-carboxylic acid chlorides.
  • monocyclic, mono-carboxylic acid chlorides such as benzoyl chloride, C 1-22 alkyl-substituted benzoyl chloride, toluoyl chloride, halogen-substituted benzoyl chloride, bromobenzoy
  • Chlorides of aliphatic monocarboxylic acids with up to 22 carbon atoms are suitable.
  • Functionalized chlorides of aliphatic monocarboxylic acids such as acryloyl chloride and methacryoyl chloride, are also suitable.
  • mono-chloroformates including monocyclic, mono- chloroformates, such as phenyl chloroformate, alkyl-substituted phenyl chloroformate, p-cumyl phenyl chloroformate, toluene chloroformate, and mixtures thereof.
  • Polyester-polycarbonate resins may be prepared by interfacial polymerization. Rather than utilizing the dicarboxylic acid per se, it is possible, and sometimes even preferred, to employ the reactive derivatives of the acid, such as the corresponding acid halides, in particular the acid dichlorides and the acid dibromides. Thus, for example instead of using isophthalic acid, terephthalic acid, or mixtures thereof, it is possible to employ isophthaloyl dichloride, terephthaloyl dichloride, and mixtures thereof.
  • Suitable phase transfer catalysts include, for example, [CH 3 (CH 2 ) 3 ] 4 NX, [CH 3 (CH 2 ) 3 ] 4 PX, [CH 3 (CH 2 ) 5 ] 4 NX, [CH 3 (CH 2 ) 6 ] 4 NX, [CH 3 (CH 2 ) 4 ] 4 NX, CH 3 [CH 3 (CH 2 ) 3 ] 3 NX, and CH 3 [CH 3 (CH 2 ) 2 ] 3 NX, wherein X is Cl " , Bf, a C 1-8 alkoxy group or a C 6-I8 aryloxy group.
  • An effective amount of a phase transfer catalyst may be 0.1 to 10 wt% based on the weight of bisphenol in the phosgenation mixture. In another embodiment an effective amount of phase transfer catalyst may be 0.5 to 2 wt% based on the weight of bisphenol in the phosgenation mixture.
  • melt processes may be used to make the polycarbonates.
  • polycarbonates may be prepared by co-reacting, in a molten state, the dihydroxy reactant(s) and a diaryl carbonate ester, such as diphenyl W
  • the polycarbonate can also include a polysiloxane-polycarbonate copolymer.
  • the polydiorganosiloxane blocks of the copolymer comprise repeating polydiorganosiloxane units of formula (8):
  • R is a C 1-13 monovalent organic radical.
  • R may be a C 1 -C 13 alkyl group, C 1 -C 13 alkoxy group, C 2 -C 13 alkenyl group, C 2 -C 13 alkenyloxy group, C 3 -C 6 cycloalkyl group, C 3 -C 6 cycloalkoxy group, C 6 -C 14 aryl group, C 6 -C 1O aryloxy group, C 7 -C 13 aralkyl group, C 7 -C 13 aralkoxy group, C 7 -C 13 alkaryl group, or C 7 -C 13 alkaryloxy group.
  • the foregoing groups may be fully or partially halogenated with fluorine, chlorine, bromine, or iodine, or a combination thereof. Combinations of the foregoing R groups may be used in the same copolymer.
  • D in formula (8) may vary widely depending on the type and relative amount of each component in the thermoplastic composition, the desired properties of the composition, and like considerations. Generally, D may have an average value of 2 to 1,000, specifically 2 to 500, and more specifically 5 to 100. In one embodiment, D has an average value of 10 to 75, and in still another embodiment, D has an average value of 40 to 60. " Where D is of a lower value, e.g., less than 40, it may be desirable to use a relatively larger amount of the polycarbonate-polysiloxane copolymer.
  • D is of a higher value, e.g., greater than 40
  • a combination of a first and a second (or more) polycarbonate-polysiloxane copolymers may be used, wherein the average value of D of the first copolymer is less than the average value of D of the second copolymer.
  • polydiorganosiloxane blocks are provided by repeating structural units of formula (9):
  • each R may be the same or different, and is as defined above; and each Ar may be the same or different, and is a substituted or unsubstituted C 6 -C 3O arylene radical, wherein the bonds are directly connected to an aromatic moiety.
  • Suitable Ar groups in formula (9) may be derived from a C 6 -C 3O dihydroxyarylene compound, for example a dihydroxyarylene compound of formula (3), (4), or (7) above. Combinations comprising at least one of the foregoing dihydroxyarylene compounds may also be used.
  • dihydroxyarlyene compounds are l,l-bis(4-hydroxyphenyl) methane, l,l-bis(4- hydroxyphenyl) ethane, 2,2-bis(4-hydroxyphenyl) propane, 2,2-bis(4-hydroxyphenyl) butane, 2,2-bis(4-hydroxyphenyl) octane, l,l-bis(4-hydroxyphenyl) propane, 1,1- bis(4-hydroxyphenyl) n-butane, 2,2-bis(4-hydroxy-l-methylphenyl) propane, 1,1- bis(4-hydroxyphenyl) cyclohexane, bis(4-hydroxyphenyl sulphide), and l,l-bis(4- hydroxy-t-butylphenyl) propane. Combinations comprising at least one of the foregoing dihydroxy compounds may also be used.
  • Such units may be derived from the corresponding dihydroxy compound of formula (10):
  • polydiorganosiloxane blocks comprises units of formula (11):
  • R and D are as described above, and each occurrence of R 1 is independently a divalent C 1 -C 3O hydrocarbylene, and wherein the polymerized polysiloxane unit is the reaction residue of its corresponding dihydroxy compound.
  • the polydiorganosiloxane blocks are provided by repeating structural units of formula (12)
  • Each R 2 in formula (12) is a divalent C 2 -C 8 aliphatic group.
  • Each M in formula (12) may be the same or different, and may be a halogen, cyano, nitro, C 1 -C 8 alkylthio, C 1 -C 8 alkyl, C 1 -C 8 alkoxy, C 2 -C 8 alkenyl, C 2 - C 8 alkenyloxy group, C 3 -C 8 cycloalkyl, C 3 -C 8 cycloalkoxy, C 6 -C 1O aryl, C 6 -C 1 O aryloxy, C 7 -Cj 2 aralkyl, C 7 -C 12 aralkoxy, C 7 -C 12 alkaryl, or C 7 -C 12 alkaryloxy, wherein each n is independently 0, 1, 2, 3, or 4.
  • M is bromo or chloro, an alkyl group such as methyl, ethyl, or propyl, an alkoxy group such as methoxy, ethoxy, or propoxy, or an aryl group such as phenyl, chlorophenyl, or tolyl;
  • R is a dimethylene, trimethylene or tetramethylene group; and
  • R is a Cj -8 alkyl, haloalkyl such as trifluoropropyl, cyanoalkyl, or aryl such as phenyl, chlorophenyl or tolyl.
  • R is methyl, or a mixture of methyl and trifluoropropyl, or a mixture of methyl and phenyl.
  • M is methoxy, n is one, R is a divalent C 1 -C 3 aliphatic group, and R is methyl.
  • Units of formula (12) may be derived from the corresponding dihydroxy polydiorganosiloxane (13):
  • dihydroxy polysiloxanes can be made by effecting a platinum catalyzed addition between a siloxane hydride of formula (14):
  • R and D are as previously defined, and an aliphatically unsaturated monohydric phenol.
  • Suitable aliphatically unsaturated monohydric phenols included, for example, eugenol, 2-allylphenol, 4-allyl-2-methylphenol, 4-allyl-2-phenylphenol, 4 ⁇ allyl-2 ⁇ bromophenol, 4-allyl-2-t-butoxyphenol, 4-phenyl-2-phenylphenol, 2-methyl- 4-propylphenol, 2 ⁇ allyl-4,6-dimethylphenol, 2-allyl-4-bromo-6-methylphenol, 2-allyl- 6-methoxy-4-methylphenol and 2-allyl-4,6-dimethylphenol. Mixtures comprising at least one of the foregoing may also be used.
  • the polysiloxane-polycarbonate can comprise 50 to 99 wt% of carbonate units and 1 to 50 wt% dimethylsiloxane units, or the molar equivalent of other diorganosiloxane units.
  • the polysiloxane-polycarbonate copolymer may comprise 70 to 98 wt%, specifically 75 to 97 wt% of carbonate units and 2 to 30 wt%, specifically 3 to 25 wt% dimethylsiloxane units, or the molar equivalent of other diorganosiloxane units.
  • the polysiloxane-polycarbonate can comprise polysiloxane units, and carbonate units derived from bisphenol A, i.e., the dihydroxy compound of formula (3) in which each of A 1 and A 2 is p-phenylene and Y is isopropylidene.
  • Polysiloxane-polycarbonates may have a weight average molecular weight of 2,000 to 100,000, specifically 5,000 to 50,000 as measured by gel permeation chromatography using a crosslinked styrene-divinyl benzene column, at a sample concentration of 1 milligram per milliliter, and as calibrated with polystyrene standards.
  • thermoplastic polymers for example combinations of polycarbonates and/or polycarbonate copolymers with polyesters.
  • a "combination" is inclusive of all mixtures, blends, alloys, reaction products, and the like.
  • Suitable polyesters comprise repeating units of formula (6), and may be, for example, poly(alkylene dicarboxylates), liquid crystalline polyesters, and polyester copolymers.
  • a branching agent for example, a glycol having three or more hydroxyl groups or a trifunctional or multifunctional carboxylic acid has been incorporated.
  • poly(alkylene terephthalates) include, but are not limited to, polyethylene terephthalate) (PET), poly(l,4-butylene terephthalate) (PBT), poly(ethylene naphthanoate) (PEN), poly(butylene naphthanoate), (PBN), (polypropylene terephthalate) (PPT), polycyclohexanedimethanol terephthalate (PCT), and combinations comprising at least one of the foregoing polyesters.
  • PTT polyethylene terephthalate
  • PBT poly(l,4-butylene terephthalate)
  • PEN poly(ethylene naphthanoate)
  • PBN poly(butylene naphthanoate)
  • PCT polycyclohexanedimethanol terephthalate
  • PCT polycyclohexanedimethanol terephthalate
  • Polycarbonate is thus present in the resin composition in an amount of 50 to 98 wt%, specifically 65 to 96 wt%, more specifically 73 to 94 wt%, and still more specifically 78 to 93 wt%, of the combined weights of the polycarbonate, acrylonitrile-styrene- acrylate terpolymer, and low gloss additive.
  • the resin composition further comprises an acrylonitrile-styrene-acrylate terpolymer (ASA), which comprises a styrene-acrylonitrile (SAN) matrix having an acrylate elastomer phase dispersed within the SAN.
  • ASA terpolymer can be a homogeneous blend of polymers and/or an interpolymer, i.e., a polymer composition having a plurality of phases, wherein the polymer phases have graft linkages and/or interpenetration of polymer chains of a first phase into a second phase.
  • the interpenetrating chains can in principle form a network within the phase into which they penetrate.
  • Acrylonitrile-styrene-acrylate terpolymers also desirably have an outer continuous phase of acrylonitrile-styrene copolymer, which is suitable for good blending properties with polycarbonate.
  • Acrylonitrile-styrene-acrylate terpolymers can comprise a phase comprising a crosslinked acrylate elastomer, a phase comprising a crosslinked styrene-acrylonitrile copolymer, and a phase comprising a linear styrene acrylonitrile copolymer.
  • styrene can comprise styrene as well as methyl substituted styrenes including, for example, alpha-methylstyrene, vinyltoluene, a combination comprising one or more of these, and the like.
  • Specific acrylonitrile-styrene-acrylate terpolymers include core-shell-type impact modifiers in a styrene-acrylonitrile (SAN) matrix.
  • the acrylate elastomer core portion of these resins may be composed of alkyl, aryl, or aryl- alkyl (also referred to as aralkyl) esters of acrylic or methacrylic acids.
  • acrylates include esterified products of C 1-3O substituted alkyl, C 3-3O substituted cycloalkyl, C 6-3 O substituted aryl, and C 7-3O substituted aralkyl alcohols.
  • Specific acrylate monomers for use in these polymers include methyl acrylate, ethyl acrylate, 1- propyl acrylate, 2-pro ⁇ yl acrylate, n-butyl acrylate, 2-butyl acrylate, 2-methylpropyl acrylate, t-butyl acrylate, n-pentyl acrylate, 2- ⁇ entyl acrylate, 3-pentyl acrylate, 2,2- dimethylpropyl acrylate, n-hexyl acrylate, cyclohexyl methacrylate, methyl cyclohexyl acrylate, heptyl acrylates, octyl acrylates, decyl acrylates, phenyl acrylate, benzyl acrylate, hydroxyethyl acrylate, 2-hydroxypropyl acrylate, combinations comprising one or more of these, and the like.
  • Methacrylate monomers may also be used, including for example methyl methacrylate, ethyl methacrylate, 1 -propyl methacrylate, 2-propyl methacrylate, n-butyl methacrylate, 2-butyl methacrylate, 2-methylpropyl methacrylate, t-butyl methacrylate, n-pentyl methacrylate, 2-pentyl methacrylate, 3- pentyl methacrylate, 2,2-dimethylpropyl methacrylate, n-hexyl methacrylate, cyclohexyl methacrylate, methyl cyclohexyl methacrylate, heptyl methacrylates, octyl methacrylates, decyl methacrylates, phenyl methacrylate, benzyl methacrylate, hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate.
  • nitrile monomers include acrylonitrile, methacrylonitrile, fumaronitrile, a combination comprising one or more of these, and the like.
  • Suitable vinyl aromatic monomers include styrene, alpha methyl styrene, vinyl toluene, chloromethyl styrene, chlorostyrene, bromostyrene, acetoxystyrene, methoxystyrene, combinations comprising one or more of these, and the like.
  • Acrylonitrile-styrene-acrylate terpolymers can be prepared by solution phase polymerization, emulsion polymerization suspension polymerization, a combination comprising at least one of these methods, and the like.
  • the core shell portion of the resin may be prepared by a process wherein the acrylate elastomer core is polymerized and a thermoplastic shell is grafted to the core.
  • a thermoplastic shell include polymethyl methacrylate, polystyrene, styrene-acrylonitrile copolymer, and other similar vinyl polymers or copolymers.
  • the acrylate or methacrylate elastomer core may be crosslinked with polyfunctional vinyl compounds including, but not limited to, divinyl benzene, 1,5-hexadiene, 1,7-octadiene, diethyleneglycol diacrylate, propylene glycol diacrylate, propylene glycol dimethacrylate.
  • polyfunctional vinyl compounds including, but not limited to, divinyl benzene, 1,5-hexadiene, 1,7-octadiene, diethyleneglycol diacrylate, propylene glycol diacrylate, propylene glycol dimethacrylate.
  • Suitable polyfunctional vinyl compounds may have the structure of formula (15):
  • each R 3 is independently hydrogen, Ci-Cn alkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 6 -C 18 aryl, or the like; each R 4 is independently halogen, C 1 -Cj 2 alkyl, C 1 -C 12 alkoxyl, C 6 -C 18 aryl, or the like; p is 2 to 4; and q is 0 to 4.
  • polyfunctional alkenyl aromatic compounds can include 1,2-divinylbenzene, 1,3- divinylbenzene, 1,4-divinylbenzene, trivinylbenzenes, 1,3-diisopropenylbenzene, 1,4- diisopropenylbenzene, and the like; and mixtures comprising at least one of the foregoing compounds.
  • the substituents may occupy any free position on the aromatic ring.
  • a suitable acryloyl-containing compound may be a polyfunctional acryloyl compound comprising at least two acryloyl moieties having the structure of formula (16):
  • R 5 and R 6 are each independently hydrogen, C 1 -C 12 alkyl, or the like; and wherein R and R 6 may be disposed either cis or trans about the carbon-carbon double bond.
  • R 5 and R 6 can each independently be hydrogen or methyl.
  • the polyfunctional acryloyl compound can comprise at least two acryloyl moieties having the structure of formula (17):
  • R -R are each independently hydrogen, C 1 -C 12 alkyl, C 2 -C 12 alkenyl, C 6 -C 18 aryl, C 7 -C 18 alkyl-substituted aryl, C 7 -C 18 aryl-substituted alkyl, C 2 -C 12 alkoxycarbonyl, C 7 -C 18 aryloxycarbonyl, C 8 -C 18 alkyl-substituted aryloxycarbonyl, C 8 -C 1S aryl-substituted alkoxycarbonyl, nitrile, formyl, carboxylate, imidate, thiocarboxylate, or the like.
  • R 7 -R 9 can each independently be hydrogen or methyl.
  • Suitable polyfunctional acryloyl compounds can further include, for example, compounds produced by condensation of an acrylic or methacrylic acid with a di- epoxide, such as bisphenol-A diglycidyl ether, butanediol diglycidyl ether, or neopentylene glycol dimethacrylate.
  • a di- epoxide such as bisphenol-A diglycidyl ether, butanediol diglycidyl ether, or neopentylene glycol dimethacrylate.
  • Specific examples include 1,4-butanediol diglycidylether di(meth)acrylate, bisphenol A diglycidylether dimethacrylate, and neopentylglycol diglycidylether di(meth)acrylate, and the like.
  • polyfunctional acryloyl monomers are the condensation of reactive acrylate or methacrylate compounds with alcohols or amines to produce the resulting polyfunctional acrylates or polyfunctional acrylamides.
  • examples include N,N-bis(2-hydroxyethyl)(meth)acrylamide, methylenebis((meth)acrylamide),
  • Specific acrylonitrile-styrene-acrylate terpolymers comprise 15 to 90 wt%, specifically 20 to 80 wt%, and more specifically 25 to 75 wt% of an uncrosslinked polymer matrix of acrylonitrile-styrene polymer.
  • the acrylonitrile-styrene polymer is grafted on a core-shell impact modifier, typically comprising about 5 to 50 wt%, specifically 7 to 45 wt%, more specifically 10 to 40 wt%, of a crosslinked (meth)acrylate elastomer core having 15 to 35 wt% crosslinked styrene acrylonitrile shell.
  • the crosslinking monomer may be typically a diacrylate of a diol.
  • acrylonitrile-styrene-acrylate terpolymers comprise acrylonitrile, styrene and/or alpha-methylstyrene, and acrylate ester.
  • the acrylonitrile-styrene-acrylate terpolymer is a styrene-acrylonitrile matrix and a core- shell impact modifier.
  • the shell is styrene- acrylonitrile copolymer and the core is a crosslinked butylacrylate rubber.
  • a suitable acrylonitrile-styrene-acrylate terpolymer has an acrylonitrile content of 12 to 26 wt%, specifically 15 to 23 wt%, and more specifically 17 to 21 wt% of the total weight of the terpolymer.
  • a suitable acrylonitrile-styrene-acrylate terpolymer has a butylacrylate rubber content of 20 to 70 wt%, specifically 30 to 60 wt%, and more specifically 42 to 47 wt% of the total weight of the terpolymer.
  • the resin composition thus comprises an acrylonitrile-styrene-acrylate terpolymer in an amount effective to maintain at least one mechanical property of the thermoplastic composition prepared therefrom, in the presence of further components.
  • Acrylonitrile-styrene-acrylate terpolymer is thus present in the resin composition in an amount of 1 to 30 wt%, specifically 2 to 25 wt%, more specifically 3 to 20 wt%, and still more specifically 4 to 15 wt%, of the combined weights of the polycarbonate, acrylonitrile-styrene-acrylate terpolymer, and low gloss additive.
  • the resin composition used in the thermoplastic composition further comprises a low gloss additive.
  • the low gloss additive comprises the reaction product of a polyepoxide and a polymer comprising an ethylenically unsaturated nitrile, and can further comprise a polycarbonate.
  • the components are reactively combined at elevated temperature to form the low gloss additive. Suitable low gloss additives and methods of preparing them are disclosed in U.S. Patent No. 5,530,062 to Bradtke, which is incorporated herein by reference.
  • Polyepoxides which are suitable for use in preparing low gloss additives include simple aliphatic diepoxides such as dodecatriene dioxide, dipentene dioxide and 1,2,7,8-diepoxyoctane; bis-glycidyl ethers/esters such as the bisglycidyl ether of bisphenol A and its condensation products; alicyclic diepoxides such as 3,4- epoxycyclohexyl 3,4-epoxycyclohexanecarboxylate and bis(3,4- epoxycyclohexylmethyl) adipate; mixed aliphatic/alicyclic diepoxides such as vinylcyclobutene dioxide, vinylcyclopentadiene dioxide and butenylcyclopentene dioxide; glycidyl ethers of novolak resins; epoxidized heterocycles such as triglycidyl isocyanurate; and epoxidized oils such as epoxidized tall oil, linseed oil
  • polyepoxides are alicyclic polyepoxides such as 3,4-epoxycyclohexyl 3,4- epoxycyclohexylcarboxylate, available under the trade name ERL-4221 from Union Carbide.
  • acrylonitrile is specifically useful, as are copolymers in which at least some of the other units are derived from a vinylaromatic compound.
  • Suitable copolymers of this type include styrene-acrylonitrile copolymers, ⁇ -methylstyrene-acrylonitrile copolymers, acrylonitrile-styrene-methacrylic acid ester terpolymers, acrylonitrile-butadiene-styrene (ABS) resins, acrylonitrile-ethyl acrylate- styrene copolymers and rubber-modified acrylonitrile-styrene-butyl acrylate polymers.
  • ABS acrylonitrile-butadiene-styrene
  • SAN copolymers are specifically useful. Suitable SAN copolymers comprise at least 5 wt%, specifically 15 to 35 wt% ethylenically unsaturated nitrile units. More specifically, a SAN copolymer comprises about 75 wt% styrene and about 25 wt% acrylonitrile units irrespective of the monomer proportions in the copolymerization mixture, and those are therefore the proportions most often used.
  • the weight average molecular weight of the addition polymer is typically about 30,000 to about 150,000.
  • a polycarbonate as described above can be added to the low gloss additive.
  • a suitable polycarbonate is derived from 2,2-bis(4- hydroxyphenyl)propane, e.g. bisphenol A.
  • the weight averaged molecular weight, as determined by gel permeation chromatography relative to polystyrene standards, of a suitable polycarbonate is generally 10,000 to 100,000.
  • the polyepoxide and ethylenically unsaturated nitrile containing copolymer are melt blended to react them in batch or continuous mode. Typically, the polymers are extruded to form the low gloss additive.
  • An epoxide ring-opening catalyst typically a sulfonic acid such as dodecylbenzenesulfonic acid, is added to the feedthroat of an extruder concurrently with the polyepoxide and ethylenically unsaturated nitrile containing polymer.
  • the polyepoxide is present in an amount of 1.5 to 6.0 wt%, and catalyst is present at about 800 to 1800 ppm relative to the amount of ethylenically unsaturated nitrile containing copolymer.
  • Water may also be introduced in an amount of 0.05 to 1.0 wt% relative to the ethylenically unsaturated nitrile containing copolymer.
  • Extrusion of the polymers is typically carried out using a twin screw extruder operating at a temperature of 220 to 300°C, and the resulting composition is obtained as a gel.
  • the low gloss additive gel is melt blended, at a temperature of up to 350 0 C, with a polycarbonate during preparation of the low gloss additive to facilitate the production of a strandable product with minimum energy input.
  • the gloss reducing efficiency of the low gloss additive gel is also improved when blended with a polycarbonate to form the low gloss additive, and therefore less of the low gloss additive gel composition is needed to produce an equivalent reduction in gloss.
  • the low gloss additive comprises 25 to 75 wt% polycarbonate and 75 to 25 wt% of the low gloss additive gel comprising the co-reacted polyepoxide and ethylenically unsaturated nitrile containing copolymer.
  • the polyepoxide and ethylenically unsaturated nitrile containing copolymer are combined with an initial portion of polycarbonate used to form the low gloss additive, and fed into the feedthroat of an extruder, and the remaining portion of the polycarbonate used to form the low gloss additive is added using a downstream feedport of the extruder.
  • a first portion of 20 to 60 wt% of the polycarbonate used to form the low gloss additive is added to the feedthroat of the extruder with the polyepoxide and ethylenically unsaturated nitrile containing polymer, and a second portion comprising 80 to 20 wt% of the polycarbonate used to form the low gloss additive (i.e., the balance of the polycarbonate used to form the low gloss additive), is added to the feedport of the extruder.
  • the thermoplastic composition thus comprises a resin composition comprising the low gloss additive, the polycarbonate, and the acrylonitrile-styrene-acrylate terpolymer.
  • the low gloss additive is present in the resin composition in an amount of 1 to 20 wt%, specifically 2 to 10 wt%, and more specifically 3 to 7 wt% of the combined weights of the polycarbonate, acrylonitrile-styrene-acrylate terpolymer, and low gloss additive.
  • a combination of a polycarbonate and the above described low gloss additive can provide low gloss performance, where the low gloss additive is present in an amount of less than 20 weight percent, but can also reduce the resultant mechanical properties of such a combination.
  • the polycarbonate and low gloss additive are immiscible polymers, such that the gels of the low gloss additive do not substantially interact with the polycarbonate, i.e., the strength of the interaction of the polycarbonate toward itself is greater than the strength of interaction between the low gloss additive gel and the polycarbonate. It is believed that the low gloss additive gels can form isolated regions within the polycarbonate that do not act to reinforce the mechanical properties of the polycarbonate, and further can act to weaken them.
  • the surface gloss of the thermoplastic composition measured at an angle of 60 degrees (°) on 3 mm colored chips, is less than or equal to 90 gloss units (GU), specifically less than or equal to 80 GU, still more specifically less than or equal to 70 GU, still more specifically less than or equal to 60 GU, and still more specifically less than or equal to 50 GU.
  • GU 90 gloss units
  • the mechanical properties of the thermoplastic composition can be measured using impact strength. Notched izod impact strength for the thermoplastic composition, is 650 to 1000 joules per meter (J/m), specifically 750 to 975 J/m, more specifically 800 to 950 J/m, as measured at 23°C on 3.12 mm molded bars using the method of ASTM D 1238-04.
  • the percent ductility measured for the thermoplastic composition is greater than or equal to 80%, specifically greater than or equal to 85%, and more specifically greater than or equal to 90%, as measured at 23°C on 3.12 mm molded bars using the method of ASTM D 1238-04.
  • ABS acrylonitrile-butadiene-styrene terpolymer
  • the 60° gloss has been observed to increase linearly with increasing loadings of impact modifiers, and may lead to increases of greater than 40 GU in gloss as the loading is increased to loadings of 30 wt% of the combined weight of terpolymer, polycarbonate, and low gloss additive. This can lead to excessively high gloss values at impact modifier loadings which provide desirable mechanical properties (such as, for example, impact strength).
  • the thermoplastic composition can include various additives ordinarily incorporated with resin compositions of this type, with the proviso that the additives are selected so as not to adversely affect the desired properties of the thermoplastic composition. Mixtures of additives may be used. Such additives may be mixed at a suitable time during the mixing of the components for forming the thermoplastic composition.
  • the thermoplastic composition may comprise a colorant such as a pigment and/or dye additive.
  • Suitable pigments include for example, inorganic pigments such as metal oxides and mixed metal oxides such as zinc oxide, titanium dioxides, iron oxides or the like; sulfides such as zinc sulfides, or the like; aluminates; sodium sulfo-silicates, sulfates, chromates, or the like; carbon blacks; zinc ferrites; ultramarine blue; Pigment Brown 24; Pigment Red 101; Pigment Yellow 119; organic pigments such as azos, di- azos, quinacridones, perylenes, naphthalene tetracarboxylic acids, flavanthrones, isoindolinones, tetrachloroisoindolinones, anthraquinones, anthanthrones, dioxazines, phthalocyanines, and azo lakes; Pigment Blue 60, Pigment Red 122, Pigment
  • Suitable dyes can be organic materials and include, for example, coumarin dyes such as coumarin 460 (blue), coumarin 6 (green), nile red or the like; lanthanide complexes; hydrocarbon and substituted hydrocarbon dyes; polycyclic aromatic hydrocarbon dyes; scintillation dyes such as oxazole or oxadiazole dyes; aryl- or heteroaryl-substituted poly (C 2-8 ) olefin dyes; carbocyanine dyes; indanthrone dyes; phthalocyanine dyes; oxazine dyes; carbostyryl dyes; napthalenetetracarboxylic acid dyes; porphyrin dyes; bis(styryl)biphenyl dyes; acridine dyes; anthraquinone dyes; cyanine dyes; methine dyes; arylmethane dyes; azo dyes; indigoid dyes, thi
  • the thermoplastic composition may include an impact modifier in addition to the ASA terpolymer, to increase its impact resistance, where the impact modifier is present in an amount that does not adversely affect the desired properties of the thermoplastic composition.
  • impact modifiers include elastomer-modified graft copolymers comprising (i) an elastomeric (i.e., rubbery) polymer substrate having a Tg less than 1O 0 C, more specifically less than -10°C, or more specifically -40° to - 8O 0 C, and (ii) a rigid polymeric superstate grafted to the elastomeric polymer substrate.
  • elastomer-modified graft copolymers may be prepared by first providing the elastomeric polymer, then polymerizing the constituent monomer(s) of the rigid phase in the presence of the elastomer to obtain the graft copolymer.
  • the grafts may be attached as graft branches or as shells to an elastomer core.
  • the shell may merely physically encapsulate the core, or the shell may be partially or essentially completely grafted to the core.
  • Suitable materials for use as the elastomer phase include, for example, conjugated diene rubbers; copolymers of a conjugated diene with less than 50 wt% of a copolymerizable monomer; olefin rubbers such as ethylene propylene copolymers (EPR) or ethylene-propylene-diene monomer rubbers (EPDM); ethylene- vinyl acetate rubbers; silicone rubbers; elastomeric C 1-8 alkyl (meth)acrylates; elastomeric copolymers of C 1-8 alkyl (meth)acrylates with butadiene and/or styrene; or combinations comprising at least one of the foregoing elastomers.
  • conjugated diene rubbers copolymers of a conjugated diene with less than 50 wt% of a copolymerizable monomer
  • olefin rubbers such as ethylene propylene copolymers (EPR) or ethylene-prop
  • Suitable conjugated diene monomers for preparing the elastomer phase are of formula (18):
  • each X b is independently hydrogen, C 1 -C 5 alkyl, or the like.
  • conjugated diene monomers that may be used are butadiene, isoprene, 1,3-heptadiene, methyl- 1,3-pentadiene, 2,3-dimethyl-l,3-butadiene, 2-ethyl-l,3-pentadiene; 1,3- and 2,4-hexadienes, and the like, as well as mixtures comprising at least one of the foregoing conjugated diene monomers.
  • Specific conjugated diene homopolymers include polybutadiene and polyisoprene.
  • Copolymers of a conjugated diene rubber may also be used, for example those produced by aqueous radical emulsion polymerization of a conjugated diene and one or more monomers copolymerizable therewith.
  • Monomers that are suitable for copolymerization with the conjugated diene include monovinylaromatic monomers containing condensed aromatic ring structures, such as vinyl naphthalene, vinyl anthracene and the like, or monomers of formula (19):
  • each X c is independently hydrogen, C 1 -C 12 alkyl, C 3 -Ci 2 cycloalkyl, C 6 -C 12 aryl, C 7 -C 12 aralkyl, C 7 -C 12 alkaryl, C 1 -C 12 alkoxy, C 3 -C 12 cycloalkoxy, C 6 -C 12 aryloxy, chloro, bromo, or hydroxy, and R is hydrogen, C 1 -C 5 alkyl, bromo, or chloro.
  • Suitable monovinylaromatic monomers include styrene, 3-methylstyrene, 3,5-diethylstyrene, 4-n-propylstyrene, alpha-methylstyrene, alpha- methyl vinyltoluene, alpha-chlorostyrene, alpha-bromostyrene, dichlorostyrene, dibromostyrene, tetra-chlorostyrene, and the like, and combinations comprising at least one of the foregoing compounds.
  • Styrene and/or alpha-methylstyrene may be used as monomers copolymerizable with the conjugated diene monomer.
  • monomers that may be copolymerized with the conjugated diene are monovinylic monomers such as itaconic acid, acrylamide, N-substituted acrylamide or methacrylamide, maleic anhydride, maleimide, N-alkyl-, aryl-, or haloaryl-substituted maleimide, glycidyl (meth)acrylates, and monomers of the generic formula (20):
  • R is hydrogen, C 1 -C 5 alkyl, bromo, or chloro
  • X c is Ci-C 12 alkoxycarbonyl, C 1 -C 12 aryloxycarbonyl, hydroxy carbonyl, or the like.
  • monomers of formula (20) include, acrylic acid, methyl (meth)acrylate, ethyl (meth)acrylate, n-butyl (meth)acrylate, t-butyl (meth)acrylate, n-propyl (meth)acrylate, isopropyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, and the like, and combinations comprising at least one of the foregoing monomers.
  • Monomers such as n-butyl acrylate, ethyl acrylate, and 2-ethylhexyl acrylate are commonly used as monomers copolymerizable with the conjugated diene monomer. Mixtures of the foregoing monovinyl monomers and monovinylaromatic monomers may also be used.
  • Suitable (meth)acrylate monomers suitable for use as the elastomeric phase may be cross-linked, particulate emulsion homopolymers or copolymers of C 1-8 alkyl (meth)acrylates, in particular C 4-6 alkyl acrylates, for example n-butyl acrylate, t-butyl acrylate, n-propyl acrylate, isopropyl acrylate, 2-ethylhexyl acrylate, and the like, and combinations comprising at least one of the foregoing monomers.
  • the C 1-8 alkyl (meth)acrylate monomers may optionally be polymerized in admixture with up to 15 wt% of comonomers of formulas (18), (19), or (20).
  • comonomers include but are not limited to butadiene, isoprene, styrene, methyl methacrylate, phenyl methacrylate, penethylmethacrylate, N-cyclohexylacrylamide, vinyl methyl ether, and mixtures comprising at least one of the foregoing comonomers.
  • a polyfunctional crosslinking comonomer may be present, for example divinylbenzene, alkylenediol di(meth)acrylates such as glycol bisacrylate, alkylenetriol tri(meth)acrylates, polyester di(meth)acrylates, bisacrylamides, triallyl cyanurate, triallyl isocyanurate, allyl (meth)acrylate, diallyl maleate, diallyl fumarate, diallyl adipate, triallyl esters of citric acid, triallyl esters of phosphoric acid, and the like, as well as combinations comprising at least one of the foregoing crosslinking agents.
  • alkylenediol di(meth)acrylates such as glycol bisacrylate, alkylenetriol tri(meth)acrylates, polyester di(meth)acrylates, bisacrylamides, triallyl cyanurate, triallyl isocyanurate, allyl (meth)acrylate, diallyl maleate, diallyl fum
  • the elastomer phase may be polymerized by mass, emulsion, suspension, solution or combined processes such as bulk-suspension, emulsion-bulk, bulk-solution or other techniques, using continuous, semibatch, or batch processes.
  • the particle size of the elastomer substrate is not critical. For example, an average particle size of 0.001 to 25 micrometers, specifically 0.01 to 15 micrometers, or even more specifically 0.1 to 8 micrometers may be used for emulsion based polymerized rubber lattices. A particle size of 0.5 to 10 micrometers, specifically 0.6 to 1.5 micrometers may be used for bulk polymerized rubber substrates. Particle size may be measured by simple light transmission methods or capillary hydrodynamic chromatography (CHDF).
  • CHDF capillary hydrodynamic chromatography
  • the elastomer phase may be a particulate, moderately cross-linked conjugated butadiene or C 4-6 alkyl acrylate rubber, and preferably has a gel content greater than 70 wt%. Also suitable are mixtures of butadiene with styrene and/or C 4-6 alkyl acrylate rubbers.
  • the elastomeric phase may provide 5 to 95 wt% of the total graft copolymer, more specifically 20 to 90 wt%, and even more specifically 40 to 85 wt% of the elastomer- modified graft copolymer, the remainder being the rigid graft phase.
  • the rigid phase of the elastomer-modified graft copolymer may be formed by graft polymerization of a mixture comprising a monovinylaromatic monomer and optionally one or more comonomers in the presence of one or more elastomeric polymer substrates.
  • the above-described monovinylaromatic monomers of formula (19) may be used in the rigid graft phase, including styrene, alpha-methyl styrene, halostyrenes such as dibromostyrene, vinyltoluene, vinylxylene, butylstyrene, para- hydroxystyrene, methoxystyrene, or the like, or combinations comprising at least one of the foregoing monovinylaromatic monomers.
  • Suitable comonomers include, for example, the above-described monovinylic monomers and/or monomers of the general formula (20).
  • R is hydrogen or C 1 -C 2 alkyl
  • X c is cyano or C 1 -C 12 alkoxycarbonyl.
  • suitable comonomers for use in the rigid phase include, methyl (meth)acrylate, ethyl (meth)acrylate, n-propyl (meth)acrylate, isopropyl (meth)acrylate, and the like, and combinations comprising at least one of the foregoing comonomers.
  • the relative ratio of monovinylaromatic monomer and comonomer in the rigid graft phase may vary widely depending on the type of elastomer substrate, type of monovinylaromatic monomer(s), type of comonomer(s), and the desired properties of the impact modifier.
  • the rigid phase may generally comprise up to 100 wt% of monovinyl aromatic monomer, specifically 30 to 100 wt%, more specifically 50 to 90 wt% monovinylaromatic monomer, with the balance being comonomer(s).
  • a separate matrix or continuous phase of ungrafted rigid polymer or copolymer may be simultaneously obtained along with the elastomer-modified graft copolymer.
  • impact modifiers comprise 40 to 95 wt% elastomer-modified graft copolymer and 5 to 65 wt% graft (co)polymer, based on the total weight of the impact modifier.
  • such impact modifiers comprise 50 to 85 wt%, more specifically 75 to 85 wt% rubber-modified graft copolymer, together with 15 to 50 wt%, more specifically 15 to 25 wt% graft (co)polymer, based on the total weight of the impact modifier.
  • the silicone rubber monomer may comprise, for example, a cyclic siloxane, tetraalkoxysilane, trialkoxysilane, (acryloxy)alkoxysilane, (mercaptoalkyl)alkoxysilane, vinylalkoxysilane, or allylalkoxysilane, alone or in combination, e.g., decamethylcyclopentasiloxane, dodecamethylcyclohexasiloxane, trimethyltriphenylcyclotrisiloxane, tetramethyltetraphenylcyclotetrasiloxane, tetramethyltetravinylcyclotetrasiloxane, octaphenylcyclotetrasiloxane., octamethylcyclotetrasiloxane and/or tetraethoxysilane.
  • a cyclic siloxane tetraalkoxysilane, trialkoxys
  • Exemplary branched acrylate rubber monomers include iso-octyl acrylate, 6- methyloctyl acrylate, 7-methyloctyl acrylate, 6-methylheptyl acrylate, and the like, alone or in combination.
  • the polymerizable, alkenyl-containing organic material may be, for example, a monomer of formula (19) or (20), e.g., styrene, alpha- methylstyrene, or an unbranched (meth)acrylate such as methyl methacrylate, 2- ethylhexyl methacrylate, methyl acrylate, ethyl acrylate, n-propyl acrylate, or the like, alone or in combination.
  • the at least one first graft link monomer may be an (acryloxy)alkoxysilane, a (mercaptoalkyl)alkoxysilane, a vinylalkoxysilane, or an allylalkoxysilane, alone or in combination, e.g., (gamma-methacryloxypropyl)(dimethoxy)methylsilane and/or (3- mercaptopropyl)trimethoxysilane.
  • the at least one second graft link monomer is a polyethylenically unsaturated compound having at least one allyl group, such as allyl methacrylate, triallyl cyanurate, or triallyl isocyanurate, alone or in combination.
  • the silicone-acrylate impact modifier compositions can be prepared by emulsion polymerization, wherein, for example at least one silicone rubber monomer is reacted with at least one first graft link monomer at a temperature from 3O 0 C to 11O 0 C to form a silicone rubber latex, in the presence of a surfactant such as dodecylbenzenesulfonic acid.
  • a surfactant such as dodecylbenzenesulfonic acid.
  • a cyclic siloxane such as cyclooctamethyltetrasiloxane and tetraethoxyorthosilicate may be reacted with a first graft link monomer such as (gamma-methacryloxypropyl) methyldimethoxysilane, to afford silicone rubber having an average particle size from 100 nanometers to 2 micrometers.
  • a first graft link monomer such as (gamma-methacryloxypropyl) methyldimethoxysilane
  • At least one branched acrylate rubber monomer is then polymerized with the silicone rubber particles, optionally in presence of a cross linking monomer, such as allylmethacrylate in the presence of a free radical generating polymerization catalyst such as benzoyl peroxide.
  • This latex is then reacted with a polymerizable alkenyl-containing organic material and a second graft link monomer.
  • the latex particles of the graft silicone- acrylate rubber hybrid may be separated from the aqueous phase through coagulation (by treatment with a coagulant) and dried to a fine powder to produce the silicone- acrylate rubber impact modifier composition.
  • This method can be generally used for producing the silicone-acrylate impact modifier having a particle size from 100 nanometers to 2 micrometers 2 micrometers.
  • Processes known for the formation of the foregoing elastomer-modified graft copolymers include mass, emulsion, suspension, and solution processes, or combined processes such as bulk-suspension, emulsion-bulk, bulk-solution or other techniques, using continuous, semibatch, or batch processes.
  • the foregoing types of impact modifiers can be prepared by an emulsion polymerization process that is free of basic materials such as alkali metal salts of C 6-3 O fatty acids, for example sodium stearate, lithium stearate, sodium oleate, potassium oleate, and the like, alkali metal carbonates, amines such as dodecyl dimethyl amine, dodecyl amine, and the like, and ammonium salts of amines.
  • Such materials are commonly used as surfactants in emulsion polymerization, and may catalyze transesterification and/or degradation of polycarbonates.
  • ionic sulfate, sulfonate or phosphate surfactants may be used in preparing the impact modifiers, particularly the elastomeric substrate portion of the impact modifiers.
  • Suitable surfactants include, for example, C 1-22 alkyl or C 7-25 alkylaryl sulfonates, C 1-22 alkyl or C 7-25 alkylaryl sulfates, C 1-22 alkyl or C 7-25 alkylaryl phosphates, substituted silicates, and mixtures thereof.
  • a specific surfactant is a C 6-16 , specifically a C 8-12 alkyl sulfonate.
  • any of the above-described impact modifiers may be used providing it is free of the alkali metal salts of fatty acids, alkali metal carbonates and other basic materials.
  • a specific impact modifier of this type is an MBS impact modifier wherein the butadiene substrate is prepared using above-described sulfonates, sulfates, or phosphates as surfactants. It is also preferred that the impact modifier have a pH of 3 to 8, specifically 4 to 7. When present, impact modifiers can be present in amounts of 0.1 to 30 percent by weight, based on 100 percent by weight of the resin composition, excluding any other additives and/or fillers.
  • the thermoplastic composition may include fillers or reinforcing agents.
  • suitable fillers or reinforcing agents include, for example, silicates and silica powders such as aluminum silicate (mullite), synthetic calcium silicate, zirconium silicate, fused silica, crystalline silica graphite, natural silica sand, or the like; boron powders such as boron-nitride powder, boron-silicate powders, or the like; oxides such as TiO 2 , aluminum oxide, magnesium oxide, or the like; calcium sulfate (as its anhydride, dihydrate or trihydrate); calcium carbonates such as chalk, limestone, marble, synthetic precipitated calcium carbonates, or the like; talc, including fibrous, modular, needle shaped, lamellar talc, or the like; wollastonite; surface-treated wollastonite; glass spheres such as hollow and solid glass spheres, silicate spheres, cenospheres, aluminosilicate
  • the fillers and reinforcing agents may be coated with a layer of metallic material to facilitate conductivity, or surface treated with silanes to improve adhesion and dispersion with the polymeric matrix resin.
  • the reinforcing fillers may be provided in the form of monofilament or multifilament fibers and may be used either alone or in combination with other types of fiber, through, for example, co- weaving or core/sheath, side-by-side, orange-type or matrix and fibril constructions, or by other methods known to one skilled in the art of fiber manufacture.
  • Suitable cowoven structures include, for example, glass fiber-carbon fiber, carbon fiber-aromatic polyimide (aramid) fiber, and aromatic polyimide fiberglass fiber or the like.
  • Fibrous fillers may be supplied in the form of, for example, rovings, woven fibrous reinforcements, such as 0-90 degree fabrics or the like; non- woven fibrous reinforcements such as continuous strand mat, chopped strand mat, tissues, papers and felts or the like; or three-dimensional reinforcements such as braids. Fillers can be used in amounts of 0 to 90 percent by weight, based on 100 percent by weight of the resin composition, excluding any other additives and/or fillers.
  • Suitable antioxidant additives include, for example, organophosphites such as tris(nonyl phenyl)phosphite, tris(2,4-di-t-butylphenyl)phosphite, bis(2,4-di-t- butylphenyl)pentaerythritol diphosphite, distearyl pentaerythritol diphosphite or the like; alkylated monophenols or polyphenols; alkylated reaction products of polyphenols with dienes, such as tetrakis[methylene(3,5-di-tert-butyl-4- hydroxyhydrocinnamate)] methane, or the like; butylated reaction products of para- cresol or dicyclopentadiene; alkylated hydroquinones; hydroxylated thiodiphenyl ethers; alkylidene-bisphenols; benzyl compounds; esters of beta-(3,5-di
  • Suitable heat stabilizer additives include, for example, organophosphites such as triphenyl phosphite, tris-(2,6-dimethylphenyl)phosphite, tris-(mixed mono-and di- nonylphenyl)phosphite or the like; phosphonates such as dimethylbenzene phosphonate or the like, phosphates such as trimethyl phosphate, or the like, or combinations comprising at least one of the foregoing heat stabilizers.
  • Heat stabilizers can be used in amounts of 0.0001 to 1 percent by weight, based on 100 percent by weight of the resin composition, excluding any other additives and/or fillers.
  • Light stabilizers and/or ultraviolent light (UV) absorbing additives may also be used.
  • Suitable light stabilizer additives include, for example, benzotriazoles such as 2-(2- hydroxy-5-methylphenyl)benzotriazole, 2-(2-hydroxy-5-tert-octylphenyl)- benzotriazole and 2-hydroxy-4-n-octoxy benzophenone, or the like, or combinations comprising at least one of the foregoing light stabilizers.
  • Light stabilizers can be used in amounts of 0.0001 to 1 percent by weight, based on 100 percent by weight of the resin composition, excluding any other additives and/or fillers.
  • Suitable UV absorbing additives include for example, hydroxybenzophenones; hydroxybenzotriazoles; hydroxybenzotriazines; cyanoacrylates; oxanilides; benzoxazinones ; 2- (2H-benzotriazol-2-yl)-4-( 1 , 1 ,3 ,3-tetramethylbutyl)-phenol (CYASORBTM 5411); 2-hydroxy-4-n-octyloxybenzophenone (CYASORBTM 531); 2- [4,6-bis(2,4-dimethylphenyl)-l,3,5-triazin-2-yl]- 5-(octyloxy)-phenol (CYASORBTM 1164); 2,2'-(l,4- phenylene)bis(4H-3,l-benzoxazin-4-one) (CYASORBTM UV- 3638); l,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy]-2,2-bis
  • Plasticizers, lubricants, and/or mold release agents additives may also be used.
  • phthalic acid esters such as dioctyl-4,5-epoxy-hexahydrophthalate; tris- (octoxycarbonylethyl)isocyanurate; tristearin; di- or polyfunctional aromatic phosphates such as resorcinol tetraphenyl diphosphate (RDP), the bis(diphenyl) phosphate of hydroquinone and the bis(diphenyl) phosphate of bisphenol-A; poly- alpha-olefins; epoxidized soybean oil; silicones, including silicone oils; esters, for example, fatty acid esters such as alkyl stearyl esters, e.g., methyl stearate; stearyl stearate, pentaerythritol tetrastearate, and the like; mixtures of methyl
  • antistatic agent refers to monomeric, oligomeric, or polymeric materials that can be processed into polymer resins and/or sprayed onto materials or articles to improve conductive properties and overall physical performance.
  • monomeric antistatic agents include glycerol monostearate, glycerol distearate, glycerol tristearate, ethoxylated amines, primary, secondary and tertiary amines, etlioxylated alcohols, alkyl sulfates, alkylarylsulfates, alkylphosphates, alkylaminesulfates, alkyl sulfonate salts such as sodium stearyl sulfonate, sodium dodecylbenzenesulfonate or the like, quaternary ammonium salts, quaternary ammonium resins, imidazoline derivatives, sorbitan esters, ethanolamides, betaines, or the like, or combinations comprising at least one of the
  • Exemplary polymeric antistatic agents include certain polyesteramides polyether- polyamide (polyetheramide) block copolymers, polyetheresteramide block copolymers, polyetheresters, or polyurethanes, each containing polyalkylene glycol moieties polyalkylene oxide units such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol, and the like.
  • polyetheramide polyether- polyamide
  • polyetheresteramide block copolymers polyetheresters, or polyurethanes
  • polyalkylene glycol moieties polyalkylene oxide units such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol, and the like.
  • Such polymeric antistatic agents are commercially available, for example PelestatTM 6321 (Sanyo) or PebaxTM MH1657 (Atofina), IrgastatTM P18 and P22 (Ciba-Geigy).
  • polymeric materials that may be used as antistatic agents are inherently conducting polymers such as polyaniline (commercially available as PANIPOL ® EB from Panipol), polypyrrole and polythiophene (commercially available from Bayer), which retain some of their intrinsic conductivity after melt processing at elevated temperatures.
  • carbon fibers, carbon nanofibers, carbon nanotubes, carbon black, or any combination of the foregoing may be used in a polymeric resin containing chemical antistatic agents to render the composition electrostatically dissipative.
  • Antistatic agents can be used in amounts of 0.0001 to 5 percent by weight, based on 100 percent by weight of the resin composition, excluding any other additives and/or fillers.
  • Suitable flame retardant that may be added may be organic compounds that include phosphorus, bromine, and/or chlorine.
  • Non-brominated and non-chlorinated phosphorus-containing flame retardants may be preferred in certain applications for regulatory reasons, for example organic phosphates and organic compounds containing phosphorus-nitrogen bonds.
  • aromatic phosphates may be, for example, phenyl bis(dodecyl) phosphate, phenyl bis(neopentyl) phosphate, phenyl bis(3,5,5'- trimethylhexyl) phosphate, ethyl diphenyl phosphate, 2-ethylhexyl di(p-tolyl) phosphate, bis(2-ethylhexyl) p-tolyl phosphate, tritolyl phosphate, bis(2-ethylhexyl) phenyl phosphate, tri(nonylphenyl) phosphate, bis(dodecyl) p-tolyl phosphate, dibutyl phenyl phosphate, 2-chloroethyl diphenyl phosphate, p-tolyl bis(2,5,5'-trimethylhexyl) phosphate, 2-ethylhexyl diphenyl phosphate,
  • Di- or polyfunctional aromatic phosphorus-containing compounds are also useful, for example, compounds of the formulas below:
  • each G is independently a hydrocarbon having 1 to 30 carbon atoms; each G is independently a hydrocarbon or hydrocarbonoxy having 1 to 30 carbon atoms; each X a is independently a hydrocarbon having 1 to 30 carbon atoms; each X is independently a bromine or chlorine; m is 0 to 4, and n is 1 to 30.
  • suitable di- or polyfunctional aromatic phosphorus-containing compounds include resorcinol tetraphenyl diphosphate (RDP), the bis(diphenyl) phosphate of hydroquinone and the bis(diphenyl) phosphate of bisphenol-A, respectively, their oligomeric and polymeric counterparts, and the like.
  • Exemplary suitable flame retardant compounds containing phosphorus-nitrogen bonds include phosphonitrilic chloride, phosphorus ester amides, phosphoric acid amides, phosphonic acid amides, phosphinic acid amides, tris(aziridinyl) phosphine oxide.
  • phosphorus-containing flame retardants can be present in amounts of 0.1 to 10 percent by weight, based on 100 percent by weight of the resin composition, excluding any other additives and/or fillers.
  • Halogenated materials may also be used as flame retardants, for example halogenated compounds and resins of formula (21):
  • R is an alkylene, alkylidene or cycloaliphatic linkage, e.g., methylene, ethylene, propylene, isopropylene, isopropylidene, butylene, isobutylene, amylene, cyclohexylene, cyclopentylidene, or the like; or an oxygen ether, carbonyl, amine, or a sulfur containing linkage, e.g., sulfide, sulfoxide, sulfone, or the like.
  • R can also consist of two or more alkylene or alkylidene linkages connected by such groups as aromatic, amino, ether, carbonyl, sulfide, sulfoxide, sulfone, or the like.
  • Ar and Ar' in formula (21) are each independently mono- or polycarbocyclic aromatic groups such as phenylene, biphenylene, terphenylene, naphthylene, or the like.
  • Y is an organic, inorganic, or organometallic radical, for example: halogen, e.g., chlorine, bromine, iodine, fluorine; ether groups of the general formula OE, wherein E is a monovalent hydrocarbon radical similar to X; monovalent hydrocarbon groups of the type represented by R; or other substituents, e.g., nitro, cyano, and the like, said substituents being essentially inert provided that there is at least one and preferably two halogen atoms per aryl nucleus.
  • halogen e.g., chlorine, bromine, iodine, fluorine
  • ether groups of the general formula OE wherein E is a monovalent hydrocarbon radical similar to X; monovalent hydrocarbon groups of the type represented by R; or other substituents, e.g., nitro, cyano, and the like, said substituents being essentially inert provided that there is at least one and preferably two halogen atom
  • each X is independently a monovalent hydrocarbon group, for example an alkyl group such as methyl, ethyl, propyl, isopropyl, butyl, decyl, or the like; an aryl groups such as phenyl, naphthyl, biphenyl, xylyl, tolyl, or the like; and aralkyl group such as benzyl, ethylphenyl, or the like; a cycloaliphatic group such as cyclopentyl, cyclohexyl, or the like.
  • the monovalent hydrocarbon group may itself contain inert substituents.
  • Each d is independently 1 to a maximum equivalent to the number of replaceable hydrogens substituted on the aromatic rings comprising Ar or Ar'.
  • Each e is independently 0 to a maximum equivalent to the number of replaceable hydrogens on R.
  • Each a, b, and c is independently a whole number, including 0. When b is not 0, neither a nor c may be 0. Otherwise either a or c, but not both, may be 0. Where b is 0, the aromatic groups are joined by a direct carbon-carbon bond.
  • the hydroxyl and Y substituents on the aromatic groups, Ar and Ar' can be varied in the ortho, meta or para positions on the aromatic rings and the groups can be in any possible geometric relationship with respect to one another.
  • 1,3-dichlorobenzene, 1,4-dibromobenzene, l,3-dichloro-4-hydroxybenzene, and biphenyls such as 2,2'- dichlorobiphenyl, polybrominated 1,4-diphenoxybenzene, 2,4'-dibromobiphenyl, and 2,4'-dichlorobiphenyl as well as decabromo diphenyl oxide, and the like.
  • oligomeric and polymeric halogenated aromatic compounds such as a copolycarbonate of bisphenol A and tetrabromobisphenol A and a carbonate precursor, e.g., phosgene.
  • Metal synergists e.g., antimony oxide, may also be used with the flame retardant.
  • halogen containing flame retardants can be present in amounts of 0.1 to 10 percent by weight, based on 100 percent by weight of the resin composition, excluding any other additives and/or fillers.
  • Inorganic flame retardants may also be used, for example salts of C 2-16 alkyl sulfonate salts such as potassium perfluorobutane sulfonate (Rimar salt), potassium perfluoroctane sulfonate, tetraethylammonium perfluorohexane sulfonate, and potassium diphenylsulfone sulfonate, and the like; salts formed by reacting for example an alkali metal or alkaline earth metal (for example lithium, sodium, potassium, magnesium, calcium and barium salts) and an inorganic acid complex salt, for example, an oxo-anion, such as alkali metal and alkaline-earth metal salts of carbonic acid, such as Na 2 CO 3 , K 2 CO 3 , MgCO 3 , CaCO 3 , and BaCO 3 or fluoro-anion complexes such as Li 3 AlF 6 , BaSiF 6 , KBF 4 , K
  • Anti-drip agents may also be used, for example a fibril forming or non-fibril forming fluoropolymer such as polytetrafluoroethylene (PTFE).
  • the anti-drip agent may be encapsulated by a rigid copolymer as described above, for example styrene- acrylonitrile copolymer (SAN).
  • SAN styrene- acrylonitrile copolymer
  • TSAN styrene- acrylonitrile copolymer
  • Encapsulated fluoropolymers may be made by polymerizing the encapsulating polymer in the presence of the fluoropolymer, for example an aqueous dispersion.
  • TSAN may provide significant advantages over PTFE, in that TSAN may be more readily dispersed in the composition.
  • a suitable TSAN may comprise, for example, 50 wt% PTFE and 50 wt% SAN, based on the total weight of the encapsulated fluoropolymer.
  • the SAN may comprise, for example, 75 wt% styrene and 25 wt% acrylonitrile based on the total weight of the copolymer.
  • the fluoropolymer may be pre-blended in some manner with a second polymer, such as for, example, an aromatic polycarbonate resin or SAN to form an agglomerated material for use as an anti-drip agent. Either method may be used to produce an encapsulated fluoropolymer.
  • Antidrip agents can be used in amounts of 0.1 to 5 percent by weight, based on 100 percent by weight of the resin composition, excluding any other additives and/or fillers.
  • Radiation stabilizers may also be present, specifically gamma-radiation stabilizers.
  • Suitable gamma-radiation stabilizers include diols, such as ethylene glycol, propylene glycol, 1,3-propanediol, 1,2-butanediol, 1,4-butanediol, meso-2,3-butanediol, 1,2- pentanediol, 2,3-pentanediol, 1,4-pentanediol, 1,4-hexandiol, and the like; alicyclic alcohols such as 1,2-cyclopentanediol, 1,2-cyclohexanediol, and the like; branched acyclic diols such as 2,3-dimethyl-2,3-butanediol (pinacol), and the like, and polyols, as well as alkoxy-substituted cyclic or acyclic al
  • Alkenols, with sites of unsaturation are also a useful class of alcohols, examples of which include 4-methyl- 4-penten-2-ol, 3-methyl-pentene-3-ol, 2-methyl-4-penten-2-ol, 2,4-dimethyl-4-pene-2- ol, and 9-decen-l-ol.
  • Another class of suitable alcohols is the tertiary alcohols, which have at least one hydroxy substituted tertiary carbon.
  • Examples of these include 2- methyl-2,4-pentanediol (hexylene glycol), 2-phenyl-2-butanol, 3-hydroxy-3-methyl-2- butanone, 2- ⁇ henyl ⁇ 2-butanol, and the like, and cycoloaliphatic tertiary carbons such as 1 -hydroxy- 1-methyl-cyclohexane.
  • Another class of suitable alcohols is hydroxymethyl aromatics, which have hydroxy substitution on a saturated carbon attached to an unsaturated carbon in an aromatic ring.
  • the hydroxy substituted saturated carbon may be a methylol group (-CH 2 OH) or it may be a member of a more complex hydrocarbon group such as would be the case with (-CR 4 HOH) or (- CR 2 OH) wherein R 4 is a complex or a simple hydrocarbon.
  • Specific hydroxy methyl aromatics may be benzhydrol, 1,3-benzenedimethanol, benzyl alcohol, 4-benzyloxy benzyl alcohol and benzyl benzyl alcohol.
  • Specific alcohols are 2-methyl-2,4- pentanediol (also known as hexylene glycol), polyethylene glycol, and polypropylene glycol.
  • Gamma-radiation stabilizing compounds are typically used in amounts of 0.001 to 1 wt %, more specifically 0.01 to 0.5 wt%, based on the resin composition, excluding any other additives and/or fillers.
  • the thermoplastic composition comprises a resin composition comprising 50 to 98 wt% of the polycarbonate; 1 to 30 wt% of acrylonitrile-styrene- acrylate terpolymer; and 1 to 20 wt% of low gloss additive.
  • the thermoplastic composition comprises a resin composition comprising 65 to 96 wt% polycarbonate, 2 to 25 wt% acrylonitrile-styrene-acrylate terpolymer; and 2 to 10 wt% of low gloss additive.
  • the thermoplastic composition comprises a resin composition comprising 73 to 94 wt% polycarbonate resin; 3 to 20 wt% acrylonitrile-styrene-acrylate terpolymer; and 3 to 7 wt% of low gloss additive.
  • the thermoplastic composition comprises a resin composition comprising 78 to 93 wt% polycarbonate resin; 4 to 15 wt% acrylonitrile-styrene- acrylate terpolymer; and 3 to 7 wt% of low gloss additive.
  • thermoplastic composition further comprises an impact modifier, filler, antioxidant, heat stabilizer, light stabilizer, ultraviolet light absorber, plasticizer, mold release agent, lubricant, antistatic agent, pigment, dye, flame retardant, anti-drip agent, or a combination comprising one or more of these.
  • thermoplastic composition may be manufactured by methods generally available in the art, for example, in one embodiment, in one manner of proceeding, powdered polycarbonate, acrylonitrile-styrene-acrylate terpolymer, low gloss additive, and/or other optional components are first blended, in a HENSCHEL-Mixers ® high speed mixer. Other low shear processes including but not limited to hand mixing may also accomplish this blending. The blend is then fed into the throat of an extruder via a hopper. Alternatively, one or more of the components may be incorporated into the composition by feeding directly into the extruder at the throat and/or downstream through a sidestuffer.
  • Additives may also be compounded into a masterbatch with a desired polymeric resin and fed into the extruder.
  • the extruder is generally operated at a temperature higher than that necessary to cause the composition to flow.
  • the extrudate is immediately quenched in a water batch and pelletized.
  • the pellets, so prepared, when cutting the extrudate may be one-fourth inch long or less as desired. Such pellets may be used for subsequent molding, shaping, or forming.
  • a method of preparing a thermoplastic composition comprises melt combining a polyepoxide, an ethylenically unsaturated nitrile containing copolymer, and an epoxide ring-opening catalyst to form the gel-type low gloss additive as a reaction product of the foregoing.
  • the reaction product can be melt combined with a first polycarbonate to form a gel-type low gloss additive.
  • a second polycarbonate, a polysiloxane-polycarbonate, and the gel-type low gloss additive are melt combined to form a resin composition.
  • the melt combining can be done by extrusion.
  • the extrusion is done with a twin-screw extruder.
  • the extruder is typically operated at a temperature of 180 to 385°C, specifically 200 to 330 0 C, more specifically 220 to 300 0 C, wherein the die temperature may be different.
  • the extruded thermoplastic composition is quenched in water and pelletized.
  • thermoplastic compositions may be molded into useful shaped articles by a variety of means such as injection molding, extrusion, rotational molding, blow molding and thermoforming to form articles such as, for example, computer and business machine housings such as housings for monitors, handheld electronic device housings such as housings for cell phones, electrical connectors, and components of lighting fixtures, ornaments, home appliances, roofs, and automobile components such as molded interior panels, fenders, decorative trim, bumpers, and the like.
  • thermoplastic composition is further illustrated by the following non-limiting examples, prepared using the components shown in Table 1.
  • the twin-screw extruder had enough distributive and dispersive mixing elements to produce good mixing between the polymer compositions.
  • the compositions are subsequently molded using a FANUC 200Oi- 200A injection molding machine. Compositions are compounded and molded at a temperature of 220 to 330 0 C, but are not limited to these temperatures.
  • Melt viscosity (MV) was determined at 1500 sec "1 , in accordance with ASTM D3835- 02.
  • Notched Izod Impact strength (NI) and percent ductility were determined on one- eighth inch (3.12 mm) bars per ASTM D256 at temperatures of 23°, 0°C, and -20 0 C, and is reported in units of Joules per meter.
  • Surface gloss was tested according to ASTM D2457 at 60° using a Garden Gloss Meter and 3 millimeter color chips and is reported in gloss units (GU) with the gloss level of standard black glass chip as 100 GU.
  • Flexural strength was determined according to ASTM D790, and is reported in megapascals (MPa). Hardness was determined according to ASTM D785, and is reported in megapascals (MPa).
  • the low gloss additive is prepared by extruding the SAN copolymer, polycarbonate, polyepoxide, and acid catalyst in the amounts shown in Table 1, above. All components were added to the feedthroat of the twin screw extruder, except that only an initial portion comprising 20 to 60 weight percent of the polycarbonate was added with these components. The remaining polycarbonate was added downstream to a feedport at about the halfway point of the extruder. The low gloss additive was extruded at a temperature of 220 to 300 0 C, quenched, and pelletized.
  • Examples 1-3, and Comparative Examples 1-9 were prepared by extrusion as described above, using the component proportions respectively given in Table 2, below.
  • the properties of the thermoplastic compositions prepared according to Examples 1-3, and Comparative Examples 1-9, are given in Table 3, below.
  • the gloss level is greater than 100 GU.
  • Baseline gloss for the polycarbonate-low gloss additive composition without ASA terpolymer is 33 GU with 5 wt% (Comp. Ex. 6).
  • ASA terpolymer present from 5-13 wt% the gloss increases from 38 to 47 GU, a difference of 9 GU (Examples 1-3).
  • Notched Izod impact strength in the absence of the low gloss additive, is comparable for polycarbonate without impact modifiers, with ABS, and with ASA (Comparative Examples 1-5).
  • the Nil performance is decreased for the polycarbonate alone (Comparative Example 6) and the polycarbonate with ABS (Comparative Examples 7-9) relative to the Examples with ASA and low gloss additive (Examples 1-3).
  • Nil performance is dramatically improved wherein ASA is added instead of ABS, particularly at 23°C.

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PCT/US2006/025527 2005-07-08 2006-06-28 Low gloss thermoplastic composition, method of making, and articles formed therefrom WO2007008450A1 (en)

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ATE475692T1 (de) 2010-08-15
CN102304278A (zh) 2012-01-04
DE602006015843D1 (de) 2010-09-09
JP2009500495A (ja) 2009-01-08
US7563846B2 (en) 2009-07-21
EP1951811A1 (en) 2008-08-06
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CN102304278B (zh) 2013-07-10
US20070010618A1 (en) 2007-01-11

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